Cut first self-aligned litho-etch patterning

ABSTRACT

The present disclosure relates to a method for performing a self-aligned litho-etch (SALE) process. In some embodiments, the method is performed by forming a first cut layer over a hard mask having a first layer and an underlying second layer. A first plurality of openings are formed within the first layer and expose the second layer at a first plurality of positions. Two or more of the first plurality of openings are separated by the first cut layer. A spacer material is selectively formed onto sidewalls of the first plurality of openings within the first layer. A second plurality of openings are then formed within the first layer. The second plurality of openings are separated by a second cut layer including the spacer material and expose the second layer at a second plurality of positions. The second layer is etched according to the first layer and the spacer material.

REFERENCE TO RELATED APPLICATION

This application is a Continuation of U.S. application Ser. No. 14/154,439 filed on Jan. 14, 2014, the contents of which is hereby incorporated by reference in its entirety.

BACKGROUND

The semiconductor industry has continually improved the speed and power of integrated circuits (ICs) by reducing the size of components (e.g., transistor devices) within the ICs. In large part, the ability to scale the size of components within an integrated chip is driven by lithographic resolution. However, in recent technology nodes tool vendors have been unable to decrease the wavelength of photolithography exposure tools (e.g., to successfully implement EUV lithography), so that developing technology nodes often have minimum feature sizes smaller than the wavelength of illumination used in the photolithography tools.

Double patterning lithography (DPL) has become one of the most promising lithography technologies for printing critical design layers (e.g., polysilicon, thin metal routing, etc.) in sub-22 nm technology nodes. However, some double patterning technologies (e.g., litho-etch, litho-etch) suffer from misalignment and overlay problems that degrade integrated chip performance. In recent years, self-aligned double patterning (SADP) has emerged as a double patterning technology that is able to avoid such misalignment and overlay errors.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates some embodiments of a flow diagram of a method of performing a self-aligned litho-etch (SALE) process.

FIG. 2 illustrates some embodiments of an integrated chip formed according to the method of performing a self-aligned litho-etch process.

FIG. 3 illustrates some embodiments of a flow diagram of a method of performing a self-aligned litho-etch process.

FIGS. 4-11 illustrate some embodiments of exemplary substrates showing a method of performing a self-aligned litho-etch process.

FIG. 12 illustrates some alternative embodiments of a flow diagram of a method of performing a self-aligned litho-etch process.

FIGS. 13-20 illustrate some embodiments of exemplary substrates showing a method of performing a self-aligned litho-etch process.

FIG. 21 illustrates a block diagram of some embodiments of a mask generation tool configured to perform self-aligned a litho-etch process.

DETAILED DESCRIPTION

The description herein is made with reference to the drawings, wherein like reference numerals are generally utilized to refer to like elements throughout, and wherein the various structures are not necessarily drawn to scale. In the following description, for purposes of explanation, numerous specific details are set forth in order to facilitate understanding. It may be evident, however, to one of ordinary skill in the art, that one or more aspects described herein may be practiced with a lesser degree of these specific details. In other instances, known structures and devices are shown in block diagram form to facilitate understanding.

Self-aligned double patterning (SADP) technologies have been useful in forming repetitive structures such as memory arrays (e.g., SRAM memory arrays). For example, the repetitive structure of SRAM memory array bit lines and/or control lines allows for a spacer layer to be formed on sidewalls of minimum pitch openings in a patterned photoresist layer formed over a substrate during a first photolithography process. After formation of the spacer layer on the sidewalls, the patterned photoresist layer can be removed using a second photolithography process, leaving spacers separated by a space smaller than that achievable by the first photolithography process (e.g., since there are two spacers within a line). The substrate can be selectively patterned according to the spacer layer to form a dense array of lines.

A cut mask may be used to form line-end to line-end spaces in the dense array of lines. However, current SADP processes provide for end-to-end spaces between shapes formed using the second photolithography process that are larger than the end-to-end spaces between shapes formed using the first photolithography process. This is because cuts of shapes formed by the first photolithography process are performed before the shapes are lithographically formed, thereby providing for a space that can be defined by a spacer material. In contrast, cuts formed by the second photolithography process are determined by the photolithography process and therefore are limited by photo resist worse top loss profile. To further decrease the size of an IC layout, such as an SRAM cell, the end-to-end space achieved by the second photolithography process should be reduced.

Accordingly, some aspects of the present disclosure relate to a method and apparatus for performing a self-aligned litho-etch process that provides for small line-end to line-end space. In some embodiments, the method comprises providing a substrate having a multi-layer hard mask having a first layer and an underlying second layer. A first cut layer is formed over the substrate. A first plurality of openings, cut according to the first cut layer, are formed to expose the second layer at a first plurality of positions corresponding to a first plurality of shapes of a SALE design layer. A spacer material is deposited onto sidewalls of the multi-layer hard mask to form a second cut layer. A second plurality of openings, cut according to the second cut layer, are formed to expose the second layer at a second plurality of positions corresponding to a second plurality of shapes of the SALE design layer. The second layer is etched according to the first and second plurality of openings. By forming the first and second cut layers prior to performing photolithography processes that form the first and second plurality of openings, the end-to-end spaces of the first and second plurality of shapes can be reduced since the end-to-end spaces are not limited by photolithography resolution.

FIG. 1 illustrates some embodiments of a flow diagram of a method 100 of performing a self-aligned litho-etch (SALE) process. The method 100 comprises a ‘cut first’ method since it increases a line-end space defined by a first cut layer formed prior to forming openings in a multi-layer hard mask that correspond to a first plurality of shapes of a SALE design layer.

At 102, a substrate is provided. In some embodiments, the substrate may comprise one or more dielectric layers disposed over a semiconductor body. In some embodiments, the substrate further comprises a multi-layer hard mask disposed over the one or more dielectric layers. The multi-layer hard mask may comprise a first layer and an underlying second layer.

At 104, a first cut layer is selectively formed over the substrate to define a first cut position for a first plurality of shapes of a self-aligned litho-etch (SALE) design layer. The first cut layer is configured to define spaces, or ‘cuts’, in the first plurality of shapes along a line-end, so as to form an end-to-end space between lines defined by the first plurality of shapes. In some embodiments, the first cut layer is formed by depositing a blocking layer over the multi-layer hard mask.

At 106, a first plurality of openings, which are cut according to the first cut layer, are formed to expose the second layer of the multi-layer hard mask. In some embodiments, the multi-layer hard mask is etched according to a first patterned photoresist layer and the first cut layer to form the first plurality of openings.

At 108, a spacer material is selectively formed over the substrate to provide a second cut layer defining a second cut position for a second plurality of shapes of the SALE design layer. The second cut layer is configured to ‘cut’ the second plurality of shapes along a line-end to form an end-to-end space between lines defined by the second plurality of shapes. In some embodiments, the first plurality of shapes are interleaved between the second plurality of shapes.

In some embodiments, the second cut layer is formed by forming a second cut layer opening within the multi-layer hard mask, at 110. A spacer material is then formed within the second cut layer opening to form the second cut layer, at 112.

At 114, a second plurality of openings, which are cut according to the second cut layer, are formed to expose the second layer of the multi-layer hard mask. In some embodiments, the multi-layer hard mask is etched according to a second patterned photoresist layer and the spacer material comprising the second cut layer to form the second plurality of openings.

At 116, the second layer of the multi-layer hard mask may be selectively etched according to the first plurality of openings and the second plurality of openings. In some embodiments, one or more of the dielectric layers of the substrate may be subsequently etched according to the second layer of the multi-layer hard mask.

Thus, by forming a first and second cut layers prior to performing photolithography processes that open the first and second plurality of openings, method 100 provides for end-to-end spaces of the first and second plurality of shapes that are not limited by photolithography resolution.

FIG. 2 illustrates some embodiments of an integrated chip 200 formed according to the method of performing a self-aligned litho-etch process.

The integrated chip 200 comprises a first plurality of shapes 204 and a second plurality of shapes 206 disposed on an integrated chip die 202. The first plurality of shapes 204 and the second plurality of shapes 206 are comprised within a SALE design layer (i.e., a design layer formed using a SALE lithography process). In some embodiments, the first plurality of shapes 204 may be formed using a first photolithography process of a SALE process, while the second plurality of shapes 206 may be formed using a second photolithography process of the SALE process. In some embodiments, the SALE design layer may comprise a gate layer or a back-end-of-the-line metallization layer, for example.

Shapes from the first plurality of shapes 204 and the second plurality of shapes 206 may be separated in a first direction 208 by a space S that is less than a minimum space achievable using a single photomask (i.e., a G0-space). For example, in integrated chip 200 a shape 204 a of the first plurality of shapes is located along a first line 205 extending in a second direction 210 and adjacent shapes, 206 a and 206 b, of the second plurality of shapes 206 are located along a second line 207 extending in the second direction 210. Shapes 206 a and 206 b are separated from shape 204 a in the first direction 208 by a space S less than a G0-space.

Two or more of the first plurality of shapes 204 aligned in the second direction 210 are disposed in a pattern having a first end-to-end space of S₁. Two or more of the second plurality of shapes 206 aligned in the second direction 210 are disposed in a pattern having a second end-to-end space of S₂. The ratio of the first and second end-to-end spaces S₁:S₂ is approximately equal to 2.5:1.

In some embodiments, integrated chip 200 may comprise an SRAM (static-random access memory) array, wherein the first plurality of shapes 204 and the second plurality of shapes 206 comprise a plurality of bit lines. In other embodiments, integrated chip 200 may comprise an SRAM (static-random access memory) array, wherein the first plurality of shapes 204 and the second plurality of shapes 206 comprise a plurality of control lines. In yet other embodiments, integrated chip 200 may comprise a back-end-of-the-line routing section or a transistor gate section.

FIG. 3 illustrates some embodiments of a flow diagram of a method 300 of performing a self-aligned litho-etch process.

While the disclosed methods (e.g., methods 100, 300, and/or 1200) are illustrated and described below as a series of acts or events, it will be appreciated that the illustrated ordering of such acts or events are not to be interpreted in a limiting sense. For example, some acts may occur in different orders and/or concurrently with other acts or events apart from those illustrated and/or described herein. In addition, not all illustrated acts may be required to implement one or more aspects or embodiments of the description herein. Further, one or more of the acts depicted herein may be carried out in one or more separate acts and/or phases.

At 302, a substrate comprising a multi-layer hard mask overlying a semiconductor body is provided. In some embodiments, the multi-layer hard mask comprises a tri-layer hard mask having an upper-layer, a central-layer, and a lower-layer.

At 304, a first cut layer is selectively formed over the multi-layer hard mask to define a first cut position for a first plurality of shapes of a SALE design layer formed using a first photolithography process of a SALE process. The first cut layer corresponds to a first cut layer configured to cut the first plurality of shapes along a line end to form an end-to-end space between lines defined by the first plurality of shapes. In some embodiments, the first cut layer may comprise a blocking layer disposed onto the multi-layer hard mask. In some embodiments, the SALE design layer may be comprised an SRAM (static random access memory) array.

At 306, a second cut layer opening is selectively formed within the multi-layer hard mask to define a second cut position for a second plurality of shapes of the SALE design layer formed using a second photolithography process of the SALE process. The second cut layer opening defines a position of a second cut layer configured to cut the second plurality of shapes along a line end to form an end-to-end space between lines defined by the second plurality of shapes. In some embodiments, the second cut layer opening may comprise an opening in the upper-layer of the multi-layer hard mask.

At 308, a first pattern transfer layer is formed over the first cut layer and the second cut layer opening.

At 310, a first masking layer is formed over the first pattern transfer layer. In some embodiments, the first masking layer may comprise a first patterned photoresist layer.

At 312, the multi-layer hard mask is selectively etched according to the first masking layer and the first cut layer to form a first plurality of openings in the multi-layer hard mask corresponding to the first plurality of shapes. In some embodiments, the upper-layer of the multi-layer hard mask is selectively etched according to the first masking layer and the first cut layer via the first pattern transfer layer to form the first plurality of openings in the upper-layer.

At 314, the first masking layer, the first pattern transfer layer, and the first cut layer are removed.

At 316, a spacer material is selectively formed to fill the second cut layer opening in the multi-layer hard mask to form a second cut layer, and onto the sidewalls of the etched multi-layer hard mask.

At 318, a second pattern transfer layer is formed over the spacer material.

At 320, a second masking layer is formed at a position overlying the second pattern transfer layer. In some embodiments, the second masking layer may comprise a second patterned photoresist layer.

At 322, the multi-layer hard mask is selectively etched according to the second masking layer and spacer material comprising the second cut layer to form a second plurality of openings corresponding to the second plurality of shapes. The second plurality of openings are defined by the multi-layer hard mask and the spacer material disposed onto sidewalls of the etched multi-layer hard mask. In some embodiments, an upper-layer of the multi-layer hard mask is selectively etched according to the second masking layer via the second pattern transfer layer to form the second plurality of openings in the upper-layer.

At 324, the central-layer of the multi-layer hard mask is selectively etched according to the first and second plurality of openings.

In some embodiments, the lower-layer of the multi-layer hard mask may be selectively etched according to the central-layer of the multi-layer hard mask, and the underlying substrate (e.g., one or more dielectric layers) may be further etched according to the lower-layer (e.g., to form openings for a thin metal layer).

FIGS. 4-11 show some embodiments of substrates that illustrate the method 300 of performing a self-aligned litho-etch process. It will be appreciated that although FIGS. 4-11 are described with respect to method 300, the illustrations are not limited to method 300.

FIG. 4 illustrates some embodiments of a cross-sectional view 400 (along cross-sectional line A-A′) and a corresponding top-view 418 of a substrate corresponding to acts 302-308.

As shown in cross-sectional view 400, a tri-layer hard mask 403 is disposed over a semiconductor body 402. The tri-layer hard mask 403 comprises a lower-layer 404, a central-layer 406, and an upper-layer 408. In some embodiments, the lower-layer 404 comprises a titanium nitride (TiN) layer disposed over the semiconductor body 402. In some embodiments, the central-layer 406 comprises a TEOS layer disposed over the TiN layer. In some embodiments, the upper-layer 408 comprises a silicon layer disposed over the TEOS layer.

A first cut layer 410 is selectively formed over the tri-layer hard mask 403 to define a first cut position for a first plurality of shapes of a SALE design layer formed using a first photolithography process of the SALE lithography process. In some embodiments, the first cut layer 410 is formed by depositing a layer of hard mask material onto the upper-layer 408 of the tri-layer hard mask 403. The layer of hard mask material is then selectively etched to remove the hard mask material in areas excluding the first cut layer 410. In some embodiments, the hard mask material may be etched using a multi-step etching process. For example, the hard mask material may be etched using a main etch with a first etching selectivity and an over etch with a much larger etching selectivity. In some embodiments, the first cut layer 410 may be deposited by way of a vapor deposition technique (e.g., chemical vapor deposition, physical vapor deposition, etc.).

In some embodiments, the hard mask material is selectively etched using an etchant having an etching selectivity that causes the hard mask material to be etched faster than the upper-layer 408 of the tri-layer hard mask 403. The etching selectivity allows for the hard mask material to be patterned without removing the underlying upper-layer 408 of the tri-layer hard mask 403. For example, in some embodiments, the first cut layer 410 may comprise titanium nitride (TiN). In such embodiments, the etching selectivity of TiN to an underlying silicon layer is 2.3 during a main etching step (i.e., the TiN layer etches 2.3 times faster than the Si layer). In other embodiments, the first cut layer 410 may comprise titanium oxide (TiO) or other films exhibiting an etching selectivity of greater than 6 with respect to the upper-layer 408 (e.g., silicon) of the tri-layer hard mask 403 (i.e., etching 6 times faster than the upper-layer 408).

A second cut layer opening 412 is selectively formed within the tri-layer hard mask 403 to define a second cut position for a second plurality of shapes of the SALE design layer formed using a second photolithography process of a SALE lithography process. In some embodiments, the second cut layer opening 412 is formed by selectively etching the upper-layer 408 of the tri-layer hard mask 403 to form an opening that exposes the underlying central-layer 406.

A first pattern transfer layer 413 is formed over the first cut layer 410 and the second cut layer opening 412. The first pattern transfer layer 413 is configured to transfer a pattern from an overlying first photoresist layer to the upper-layer 408 of the tri-layer hard mask 403. In some embodiments, the first pattern transfer layer 413 may comprise a bottom layer 414 formed over the first cut layer 410 and the second cut layer opening 412, and a middle layer 416 formed over the bottom layer 414. In some embodiments, the bottom layer 414 may comprise a carbon layer or a hydrogen layer deposited using a vapor deposition technique or a spin-on technique. In some embodiments, the middle layer 416 may comprise a silicon oxide.

FIG. 5 illustrates some embodiments of a cross-sectional view 500 of a substrate corresponding to act 310.

As shown in cross-sectional view 500, a first patterned photoresist layer 502 is formed over the first pattern transfer layer 413. The first patterned photoresist layer 502 comprises openings 504 that correspond to locations of the first plurality of design shapes on the SALE design layer. In some embodiments, the first patterned photoresist layer 502 may be deposited by way of a spin-coating process. The first patterned photoresist layer 502 is subsequently patterned by way of a photo-lithography process that selectively exposes the first patterned photoresist layer 502 to radiation having a pattern corresponding to a photomask. Selective areas of the first patterned photoresist layer 502 are subsequently removed by a developer to form the openings 504.

FIG. 6 illustrates some embodiments of a cross-sectional view 600 and a corresponding top-view 606 of a substrate corresponding to act 312.

As shown in cross-sectional view 600, the upper-layer 602 of the tri-layer hard mask 403 is etched according to the first patterned photoresist layer 502 and the first cut layer 410 to form a first plurality of openings 604 in the upper-layer 602 corresponding to the first plurality of shapes. Etching the tri-layer hard mask 403 selectively removes portions of the upper-layer 602 of the tri-layer hard mask 403 to form the first plurality of openings 604, which expose the central-layer 406. Since the first cut layer 410 comprises a blocking layer overlying the upper-layer 602 of the tri-layer hard mask 403 the underlying central-layer 406 of the tri-layer hard mask 403 is not exposed in the area of the first cut layer 410. Since the second cut layer opening 412 comprises an opening in the upper-layer 602, the underlying central-layer 406 is exposed in the area of second cut layer opening 412.

In some embodiments, the upper-layer 602 of the tri-layer hard mask 403 is etched using an etchant having an etching selectivity that causes the upper-layer 602 to be etched faster than the first cut layer 410. Such an etching selectivity allows for the upper-layer 602 to be patterned in areas not covered by the first cut layer 410. For example, in some embodiments, the first cut layer 410 may comprise titanium nitride (TiN) and the upper-layer 602 may comprise silicon. In such embodiments, the etching selectivity of the TiN to the underlying silicon is between approximately 6 and 20 during a main etching step (i.e., the silicon etches between 6 and 20 times faster than the TiN layer). In some embodiments, the silicon may be etched using a multi-step etching process (e.g., a main etch with a first etching selectivity and an over etching step using a much larger etching selectivity).

In some embodiments, the upper-layer 602 may be etched via the first pattern transfer layer 413. For example, the middle layer 416 may be selectively etched according to the first patterned photoresist layer 502 to transfer the pattern of the first patterned photoresist layer 502 to the middle layer 416. Similarly, the bottom layer 414 is selectively etched according to the middle layer 416 to transfer the pattern of the middle layer 416 to the bottom layer 414. By transferring the pattern of the first patterned photoresist layer 502 to the upper-layer 602 of the tri-layer hard mask 403, the first pattern transfer layer 413 improves critical dimension (CD) control of the upper-layer 602 (e.g., roughness and verticalness of resist pattern that could affect the CD uniformity of final pattern are reduced).

As shown in top-view 606, the first plurality of openings 604 formed by etching the upper-layer 602 of the tri-layer hard mask 403 according to the first patterned photoresist layer 502 and the first cut layer intersect the second cut layer opening 412 to form an ‘H’ shaped opening in the upper-layer 602 of the tri-layer hard mask 403. The first plurality of openings 604 further abut the first cut layer 410 in a manner such that the first cut layer 410 separates openings 604 a and 604 b.

FIG. 7 illustrates some embodiments of a cross-sectional view 700 and a corresponding top-view 702 of a substrate corresponding to act 314.

As shown in cross-sectional view 700, the first cut layer 410 is removed. In some embodiments, the first cut layer 410 may be removed by an etchant having an etching selectivity that etches first cut layer 410 faster than the upper-layer 602 of the multi-layer hard mask.

As shown in top-view 702, removal of the first cut layer 410 results in the upper-layer 602 of the tri-layer hard mask 403 extending between openings 604 a and 604 b. The width of the upper-layer 602 of the tri-layer hard mask 403 between openings 604 a and 604 b is S₀.

FIG. 8 illustrates some embodiments of a cross-sectional view 800 and a corresponding top-view 808 of a substrate corresponding to act 314.

As shown in cross-sectional view 800, a spacer material 802 is formed onto sidewalls of openings in the etched upper-layer 602 of the tri-layer hard mask 403. The spacer material 802 fills the second cut layer opening 412 in the multi-layer hard mask 403 to form a second cut layer 806. In some embodiments, the spacer material 802 may be formed by depositing spacer material over the substrate and by subsequently etching the spacer material to remove the spacer material from horizontal surfaces. The resulting spacer material 802 remains on sidewalls of the etched upper-layer 602 of the tri-layer hard mask 403 leaving reduced width openings 804 exposing the underlying central-layer 406 of the tri-layer hard mask 403 at locations defining the first plurality of shapes.

As shown in top-view 808, the spacer material 802 forms a border around the openings 804 in the upper-layer 602 of the tri-layer hard mask 403, thereby reducing the width of openings 804 exposing the central-layer 406 of the tri-layer hard mask 403. The spacer material 802 forms a first end-to-end space S₁ between openings 804 a and 804 b.

FIG. 9 illustrates some embodiments of a cross-sectional view 900 of a substrate corresponding to acts 318-320.

As shown in cross-sectional view 900, a second pattern transfer layer 901 is formed overly the spacer material 802. In some embodiments, the second pattern transfer layer 901 comprises a bottom layer 902 deposited over the spacer material 802 and a middle layer 904 deposited over the bottom layer 902. A second patterned photoresist layer 906 is formed over the second pattern transfer layer 901. The second patterned photoresist layer 906 comprises openings 908 that correspond to locations of the second plurality of shapes of the SALE design layer.

FIG. 10 illustrates some embodiments of a cross-sectional view 1000 and a corresponding top-view 1006 of a substrate corresponding to act 322.

As shown in cross-sectional view 1000, the upper-layer 1002 of the tri-layer hard mask 403 is selectively etched according to the second patterned photoresist layer 906 and the spacer material 802 comprising the second cut layer 806 to form a second plurality of openings 1004 corresponding to the second plurality of shapes. Etching the upper-layer 1002 removes portions of the upper-layer 1002 of the tri-layer hard mask 403 to form the second plurality of openings 1004, which expose the central-layer 406. As shown in top-view 1006, the second cut layer 806 forms a second end-to-end space S₂ between openings 1004 a and 1004 b. A ratio of the first end-to-end space S₁ to the second end-to-end space S₂ is approximately equal to 2.5:1.

FIG. 11 illustrates some embodiments of a cross-sectional view 1100 and a corresponding top-view 1108 of a substrate corresponding to act 324.

As shown in cross-sectional view 1100 and top-view 1108, the central-layer 1102 of the tri-layer hard mask 403 is selectively etched according to the first and second plurality of openings, 604 and 1004, defined by the upper-layer 1002 and the spacer material 802, to respectively form openings 1104 and 1106 in the central-layer 1102.

FIG. 12 illustrates some alternative embodiments of a flow diagram of a method 1200 of performing a self-aligned litho-etch process.

At 1202, a substrate comprising a cut definition layer disposed over a multi-layer hard mask overlying a semiconductor body is provided. In some embodiments, the multi-layer hard mask comprises a tri-layer hard mask having an upper-layer, a central-layer, and a lower-layer. In some embodiments, the cut definition layer may comprise a bottom layer, a middle layer, a hard mask layer, and a blocking layer. In some embodiments, the middle layer and the blocking layer may comprise a first low-temperature film, while the hard mask layer may comprise a different second low-temperature film.

At 1204, a first cut layer is selectively formed over the cut definition layer to define a first cut position for a first plurality of shapes of a SALE design layer formed using a first photolithography process of a SALE process. In some embodiments, the first cut layer may comprise a blocking layer disposed onto the hard mask layer.

At 1206, a second cut layer opening is selectively formed within the cut definition layer to define a second cut position for a second plurality of shapes of the SALE design layer formed using a second photolithography process of the SALE process. In some embodiments, the second cut layer opening may comprise an opening in the hard mask layer.

At 1208, a first pattern transfer layer is formed over the first cut layer and the second cut layer opening.

At 1210, a first masking layer is formed over the first pattern transfer layer. In some embodiments, the first masking layer may comprise a first patterned photoresist layer.

At 1212, the cut definition layer is selectively etched according to a first masking layer and the first cut layer. In some embodiments, the cut definition layer is selectively etched via the first pattern transfer layer.

At 1214, the first masking layer and the first pattern transfer layer are removed.

At 1216, the multi-layer hard mask is selectively etched according to the cut definition layer and the second cut layer to form a first plurality of openings in the multi-layer hard mask corresponding to the first plurality of shapes. Etching the multi-layer hard mask according to the second cut layer forms a multi-layer second cut layer opening in the multi-layer hard mask.

At 1218, the cut definition layer is removed.

At 1220, a spacer material is selectively formed to fill the multi-layer second cut layer opening to form a second cut layer, and onto the sidewalls of the etched multi-layer hard mask

At 1222, a second pattern transfer layer is formed over the spacer material.

At 1224, a second masking layer is formed over the second pattern transfer layer. In some embodiments, the second masking layer may comprise a second patterned photoresist layer.

At 1226, the multi-layer hard mask is selectively etched according to the second masking layer and spacer material comprising the second cut layer to form a second plurality of openings corresponding to the second plurality of shapes. The second plurality of openings are defined by the multi-layer hard mask and the spacer material disposed onto sidewalls of the etched multi-layer hard mask. In some embodiments, the multi-layer hard mask is selectively etched via the second pattern transfer layer to form the second plurality of openings in the upper-layer.

At 1228, the central-layer of the multi-layer hard mask is selectively etched according to the first and second plurality of opening.

In some embodiments, the lower-layer of the multi-layer hard mask may be selectively etched according to the central-layer of the multi-layer hard mask. In some embodiments, and the underlying substrate (e.g., one or more dielectric layers) may be further etched according to the lower-layer (e.g., to form openings for a thin metal layer).

FIGS. 13-20 show some embodiments of substrates that illustrate the method 1200 of performing a self-aligned litho-etch process. It will be appreciated that although FIGS. 13-20 are described with respect to method 1200, the illustrations are not limited to method 1200.

FIG. 13 illustrates some embodiments of a cross-sectional view 1300 and a corresponding to acts 1202-1206.

As shown in cross-sectional view 1300, a tri-layer hard mask 403 is disposed over a semiconductor body 402. The tri-layer hard mask 403 comprises a lower-layer 404, a central-layer 406, and an upper-layer 1302. In some embodiments, the lower-layer 404 comprises a titanium nitride (TiN) layer disposed over the semiconductor body 402. In some embodiments, the central-layer 406 comprises a TEOS layer disposed over the TiN layer. In some embodiments, the upper-layer 1302 of comprises a silicon layer disposed over the TEOS layer.

A cut definition layer 1301 is disposed over the tri-layer hard mask 403. The cut definition layer 1301 comprises a bottom layer 1304, a middle layer 1306, a hard mask layer 1308, and a blocking layer 1310. In some embodiments, the bottom layer 1304 comprises a carbon layer. In some embodiments, the middle layer 1306 and the blocking layer 1310 may comprise a first low-temperature film, while the hard mask layer 1308 comprises a different, second low-temperature film.

In some embodiments, the first low-temperature film of the middle layer 1306 and the blocking layer 1310 comprise a low-temperature oxide film. In some embodiments, the second low-temperature film of the hard mask layer 1308 comprises a low-temperature TiN film. In some embodiments the low-temperature oxide film and the low-temperature TiN film are formed at a temperature having a range of between approximately 100° C. and approximately 200° C. In other embodiments, the first low-temperature film and the second low-temperature film may comprise other materials having an etching selectivity of greater than 6 (i.e., the first low-temperature film etches more than 6 times faster than the second low-temperature film).

The blocking layer is selectively etched to form a first cut layer disposed over the hard mask layer 1308. The first cut layer defines a first cut position for a first plurality of shapes of a SALE design layer formed using a first photolithography process of a SALE lithography process. A second cut layer opening 1312 is selectively formed within the hard mask layer 1308 to define a second cut position for a second plurality of shapes of the SALE design layer formed using a second photolithography process of the SALE lithography process. In some embodiments, the second cut layer opening 1312 is formed by selectively etching the hard mask layer 1308 to form an opening.

FIG. 14 illustrates some embodiments of a cross-sectional view 1400 of a substrate corresponding to acts 1208-1210.

As shown in cross-sectional view 1400, a first pattern transfer layer 1401 is formed over the first cut layer 1310 and the second cut layer opening 1312. A first patterned photoresist layer 1406 is formed over the first pattern transfer layer 1401. The first patterned photoresist layer 1406 comprises openings 1408 that correspond to locations of the first plurality of shapes.

The first pattern transfer layer 1401 is configured to transfer a pattern from an overlying first patterned photoresist layer 1406 to the hard mask layer 1308. In some embodiments, the first pattern transfer layer 1401 may comprise a bottom layer 1402 formed over the first cut layer 1310 and the second cut layer opening 1312, and a middle layer 1404 formed over the bottom layer 1402. In some embodiments, the bottom layer 1402 may comprise a carbon layer or a hydrogen layer deposited using a vapor deposition technique or a spin-on technique. In some embodiments, the middle layer 1404 may comprise a silicon oxide layer.

FIG. 15 illustrates some embodiments of a cross-sectional view 1500 and a corresponding top-view 1506 of a substrate corresponding to act 1212.

As shown in cross-sectional view 1500, hard mask layer 1502 (e.g., corresponding to 1308) is etched according to the first patterned photoresist layer 1406 and the first cut layer 1310. Etching the hard mask layer 1502 selectively removes portions of the hard mask layer 1502 to form openings 1504 that expose middle layer 1306. Since the first cut layer 1310 comprises a blocking layer overlying the hard mask layer 1308, the middle layer 1306 is not exposed in the area of the first cut layer 1310. Since the second cut layer opening 1312 comprises an opening in hard mask layer 1308, the middle layer 1306 is exposed in the area of second cut layer opening 1312.

As shown in top-view 1506, the openings 1504 formed by etching the hard mask layer 1308 of the tri-layer hard mask 403 according to the first patterned photoresist layer 1406 intersect the second cut layer opening 1312 to form an ‘H’ shaped opening in the hard mask layer 1308. The openings 1504 further abut the first cut layer 1310, in a manner such that the first cut layer 1310 separates openings 1504 a and 1504 b.

FIG. 16 illustrates some embodiments of a cross-sectional view 1600 and a corresponding top-view 1608 of a substrate corresponding to act 1214-1218.

As shown in cross-sectional view 1600, upper-layer 1602 of the tri-layer hard mask 403 is selectively etched according to the cut definition layer 1301 causing openings in the hard mask layer 1308 to be transferred as a first plurality of openings 1604 in the upper-layer 1602, which correspond to the first plurality of shapes. The cut definition layer 1301 is then removed. As shown in top-view 1608, the resulting upper-layer 1602 of the tri-layer hard mask 403 extends between openings 1604 a and 1604 b.

FIG. 17 illustrates some embodiments of a cross-sectional view 1700 and a corresponding top-view 1704 of a substrate corresponding to act 1220.

As shown in cross-sectional view 1700, a spacer material 802 is formed onto sidewalls of the etched upper-layer 1602 of the tri-layer hard mask 403. The spacer material 802 fills the second cut layer opening 1312 in the multi-layer hard mask 403 to form a second cut layer 1702. In some embodiments, the spacer material 802 may be formed by depositing spacer material over the substrate and by subsequently etching the spacer material to remove the spacer material from horizontal surfaces. The resulting spacer material 802 remains on sidewalls of the etched upper-layer 1602 of the tri-layer hard mask 403 leaving a reduced width opening 804 exposing the underlying central-layer 406 of the tri-layer hard mask 403 at locations defining the first plurality of shapes.

As shown in top-view 1704, the spacer material 802 forms a border around the openings 1606 in the upper-layer 1602 of the tri-layer hard mask 403, thereby reducing the width of exposed regions of the middle-layer 406 of the tri-layer hard mask 403.

FIG. 18 illustrates some embodiments of a cross-sectional view 1800 of a substrate corresponding to acts 1222-1224.

As shown in cross-sectional view 1800, a second pattern transfer layer 1801 is formed a position overlying the spacer material 802. In some embodiments, the second pattern transfer layer 1801 comprises a bottom layer 1802 deposited over the spacer material 802, and a middle layer 1804 deposited over the bottom layer 1802. A second patterned photoresist layer 1806 is formed over the second pattern transfer layer 1801. The second patterned photoresist layer 1806 comprises openings 1808 that correspond to locations of the second plurality of shapes.

FIG. 19 illustrates some embodiments of a cross-sectional view 1900 and a corresponding top-view 1906 of a substrate corresponding to act 1226.

As shown in cross-sectional view 1900, the upper-layer 406 of the tri-layer hard mask 403 is selectively etched according to the second patterned photoresist layer 1806 and the spacer material 802 comprising the second cut layer 1702. Etching the upper-layer 406 of the tri-layer hard mask 403 forms a second plurality of openings 1904 corresponding to the second plurality of shapes. The second plurality of openings 1904 that expose the underlying central-layer 406 of the tri-layer hard mask 403.

FIG. 20 illustrates some embodiments of a cross-sectional view 2000 and a corresponding top-view 2008 of a substrate corresponding to act 1228.

As shown in cross-sectional view 2000 and top-view 2008, the central-layer 1102 of the tri-layer hard mask 403 is selectively etched according to the first and second plurality of openings, 804 and 1904, defined by the upper-layer 1902 of the tri-layer hard mask 403 and the spacer material 802, to respectively form openings 2004 and 2006 in the central-layer 2002.

FIG. 21 illustrates a block diagram of some embodiments of a mask generation tool 2100 configured to perform self-aligned a litho-etch process

The mask generation tool 2100 comprises a memory element 2102. In various embodiments the memory element 2102 may comprise an internal memory or a computer readable medium. The memory element 2102 is configured to store an integrated chip (IC) layout 2104 comprising a graphical representation of an integrated chip. The IC layout 2104 comprises a first plurality of shapes of a self-aligned litho-etch (SALE) design layer formed using a first SALE lithography process and a second plurality of shapes of the design layer formed using a second SALE lithography process. In some embodiments, the SALE design layer may comprise a design layer within a static random access memory (SRAM) cell. In some embodiments, the IC layout 2104 may comprise a GDS or GDSII file, a CIF file, an OASIS file, or other similar file formats.

The memory element 2102 is further configured to store first cut layer data 2106 and second cut layer data 2108. The first cut layer data 2106 defines a first cut position for the first plurality of shapes of the SALE design layer. The second cut layer data 2108 defines a second cut position for the second plurality of shapes of the SALE design layer. In some embodiments, the memory element 2102 is further configured to store computer readable instructions 2110. The computer readable instructions 2110 may provide for a method of operating one or more components of the mask generation tool according to a disclosed method (e.g., method 100, 300, or 1200).

A mask cut placement tool 2112 is configured to access the IC layout 2104 and to determine a position of the first and second cut layers. For example, in some embodiments, the mask cut placement tool 2112 is configured to determine a location of a first cut within the first plurality of shapes from the first cut layer data 2106, and to determine a location of a second cut within the first second of shapes from the second cut layer data 2108.

A mask writing tool 2114 is configured to access the first cut layer data 2106 and the second cut layer data 2108. Based upon the first cut layer data 2106, the mask writing tool 2114 is configured to generate a first cut mask. Based upon the second cut layer data 2108, the mask writing tool 2114 is configured to generate a second cut mask. The first cut mask is configured to cut the first plurality of shapes and the second cut mask is configured to cut the second plurality of shapes.

It will be appreciated that equivalent alterations and/or modifications may occur to one of ordinary skill in the art based upon a reading and/or understanding of the specification and annexed drawings. The disclosure herein includes all such modifications and alterations and is generally not intended to be limited thereby. For example, although the disclosed IC layouts are illustrated as comprising a plurality of design shapes comprising square or rectangles, it will be appreciated that such shapes are not limiting. Rather, the disclosed method and apparatus may be applied to designs having design shapes of any geometry allowed by design rules.

In addition, while a particular feature or aspect may have been disclosed with respect to only one of several implementations, such feature or aspect may be combined with one or more other features and/or aspects of other implementations as may be desired. Furthermore, to the extent that the terms “includes”, “having”, “has”, “with”, and/or variants thereof are used herein, such terms are intended to be inclusive in meaning—like “comprising.” Also, “exemplary” is merely meant to mean an example, rather than the best. It is also to be appreciated that features, layers and/or elements depicted herein are illustrated with particular dimensions and/or orientations relative to one another for purposes of simplicity and ease of understanding, and that the actual dimensions and/or orientations may differ substantially from that illustrated herein.

Therefore, the present disclosure relates to a method and apparatus for performing a self-aligned litho-etch process.

In some embodiments, the present disclosure relates to a method of performing a self-aligned litho-etch process. The method comprises forming a first cut layer over a hard mask comprising a first layer and an underlying second layer disposed over a substrate. The method further comprises forming a first plurality of openings within the first layer that expose the second layer at a first plurality of positions, wherein two or more of the first plurality of openings are separated by the first cut layer. The method further comprises selectively forming a spacer material onto sidewalls of the first plurality of openings within the first layer. The method further comprises forming a second plurality of openings within the first layer, which are separated by a second cut layer comprising the spacer material, to expose the second layer at a second plurality of positions. The method further comprises etching the second layer according to the first layer and the spacer material.

In other embodiments, the present disclosure relates to a method of performing a self-aligned litho-etch process. The method comprises forming a first cut layer over a hard mask comprising a first layer and an underlying second layer disposed over a substrate. The method further comprises forming a cut opening within the first layer, and forming a first plurality of openings within the first layer that are separated by the first cut layer. The method further comprises forming a second plurality of openings within the first layer that are connected by the cut opening. The method further comprises selectively forming a spacer material onto sidewalls of the first layer, and etching the second layer according to the first layer and the spacer material.

In yet other embodiments, the present disclosure relates to a method of semiconductor processing. The method comprises forming a masking structure having a plurality of openings over a second masking layer, and patterning the second masking layer according to the masking structure to form a first plurality of openings within the second masking layer and a second plurality of openings within the second masking layer. One or more of the first plurality of openings are separated from one or more of the second plurality of openings in a first direction by a side-to-side space that is smaller than a space resolvable by a single lithographic exposure. The first plurality of openings are arranged in the first direction along a first pitch and have one or more openings separated in a second direction by a first end-to-end space, and the second plurality of openings are arranged in the first direction between adjacent ones of the first plurality of openings and have one or more openings separated in the second direction by a second end-to-end space. A ratio of the first end-to-end space to the second end-to-end space is approximately equal to 2.5:1. 

What is claimed is:
 1. A method of performing a self-aligned litho-etch (SALE) process, comprising: forming a first cut layer over a hard mask comprising a first layer and an underlying second layer disposed over a substrate; forming a first plurality of openings within the first layer that expose the second layer at a first plurality of positions, wherein two or more of the first plurality of openings are separated by the first cut layer; selectively forming a spacer material onto sidewalls of the first plurality of openings within the first layer; forming a second plurality of openings within the first layer, which are separated by a second cut layer comprising the spacer material, to expose the second layer at a second plurality of positions; and etching the second layer according to the first layer and the spacer material.
 2. The method of claim 1, wherein second cut layer continuously extends between two sidewalls of the first layer.
 3. The method of claim 1, wherein the two or more of the first plurality of openings are formed after the first cut layer is formed over the hard mask.
 4. The method of claim 1, wherein the first cut layer comprises titanium nitride or titanium oxide.
 5. The method of claim 1, further comprising: forming a first pattern transfer layer over the first cut layer; lithographically patterning a first photoresist layer overlying the first pattern transfer layer; and etching the hard mask according to the first photoresist layer and the first cut layer to form the first plurality of openings.
 6. The method of claim 5, further comprising: removing the first photoresist layer, the first pattern transfer layer, and the first cut layer after etching the hard mask according to the first photoresist layer and the first cut layer.
 7. The method of claim 6, further comprising: forming a second pattern transfer layer over the spacer material; lithographically patterning a second photoresist layer overlying the second pattern transfer layer; and etching the hard mask according to the second photoresist layer and the spacer material comprising the second cut layer to from the second plurality of openings.
 8. The method of claim 1, wherein etching the second layer according to the first layer and the spacer material results in a first end-to-end space between a first set of openings in the second layer that is equal to a width of the first cut layer added to twice a width of the spacer material; and wherein etching the second layer according to the first layer and the spacer material results in a second end-to-end space between a second set of openings in the second layer that is equal to twice the width of the spacer material.
 9. The method of claim 8, wherein a ratio of the first end-to-end space to the second end-to-end space is approximately equal to 2.5:1.
 10. The method of claim 1, wherein the two or more of the first plurality of openings are separated along a first direction; and wherein the first plurality of openings are separated from the second plurality of openings in a second direction that is perpendicular to the first direction.
 11. A method of performing a self-aligned litho-etch (SALE) process, comprising: forming a cut layer over a hard mask comprising a first layer and an underlying second layer disposed over a substrate; forming a cut opening within the first layer; forming a first plurality of openings within the first layer that are separated by the cut layer; forming a second plurality of openings within the first layer that are connected by the cut opening; selectively forming a spacer material onto sidewalls of the first layer; and etching the second layer according to the first layer and the spacer material.
 12. The method of claim 11, wherein the first plurality of openings are separated by the cut layer along a first direction; and wherein the second plurality of openings are connected by the cut opening along a second direction that is perpendicular to the first direction.
 13. The method of claim 11, wherein etching the second layer according to the first layer and the spacer material results in a first end-to-end space between a first set of openings in the second layer that is equal to a width of the cut layer added to twice a width of the spacer material; and wherein etching the second layer according to the first layer and the spacer material results in a second end-to-end space between a second set of openings in the second layer that is equal to twice the width of the spacer material.
 14. The method of claim 11, wherein the spacer material continuously extends between sidewalls of the cut opening.
 15. The method of claim 11, further comprising: etching the substrate according to the second layer to form a plurality of substrate openings within the substrate.
 16. The method of claim 15, wherein the substrate comprises a dielectric layer and the plurality of substrate openings comprise trenches for a metal interconnect layer.
 17. A method of semiconductor processing, comprising: forming a masking structure having a plurality of openings over a second masking layer; patterning the second masking layer according to the masking structure to form a first plurality of openings within the second masking layer and a second plurality of openings within the second masking layer; wherein one or more of the first plurality of openings are separated from one or more of the second plurality of openings in a first direction by a side-to-side space that is smaller than a space resolvable by a single lithographic exposure; wherein the first plurality of openings are arranged in the first direction along a first pitch and have one or more openings separated in a second direction by a first end-to-end space, and the second plurality of openings are arranged in the first direction between adjacent ones of the first plurality of openings and have one or more openings separated in the second direction by a second end-to-end space; and wherein a ratio of the first end-to-end space to the second end-to-end space is approximately equal to 2.5:1.
 18. The method of claim 17, wherein the first plurality of openings comprise a first opening arranged between adjacent ones of the second plurality of openings in the first direction.
 19. The method of claim 17, wherein forming the masking structure, comprises: forming a cut layer over a first masking layer arranged on the second masking layer; forming a cut opening within the first masking layer; forming a first plurality of openings within the first masking layer that are separated by the cut layer; forming a second plurality of openings within the first masking layer that are connected by the cut opening; and selectively forming a spacer material onto sidewalls of the first masking layer.
 20. The method of claim 19, wherein the spacer material continuously extends between sidewalls of the cut opening. 